Metal cellular flooring section and method of making the same



F. W. FORK Feb. 11', 1969 METAL CELLULAR FLOORING SECTION AND METHOD OFMAKING THE SAME Filed Oct. 18, 1966 Sheet Feb. 11, 1969 F. w. FORK3,426,492 METAL CELLULAR FLOORING SECTION AND METHOD OF MAKING THE SAMEFiled 00f. 18, 1966 Sheet 2 of 2 m mvrm FRANK m Ffl/P/f ,4 TTOR/VE)United States Patent 8 Claims ABSTRACT OF THE DISCLOSURE A metalcellular flooring section providing a plurality of spaced, generallyparallel cells, each pair of adjacent cells presenting spaced crests,confronting side walls, and an intermediate valley disposed between theconfronting side walls. Opposed openings, one in each of the confrontingside walls, provide communication at one location in the flooringsection, between the interiors of the adjacent cells and the space abovethe intermediate valley.

This invention relates to metal celluar flooring sections of the typeadapted to be supported horizontally and thereafter to receive andsupport a layer of concrete, and more particularly to an improved metalcellular flooring section of the type described, having prepunchedopenings therein which provide relatively easy access to selected cellsof said flooring section and a method of making said section.

Metal cellular flooring sections of the type described are well known inthe prior art. See, for example, US. Patent Nos. 2,041,965, 2,125,366and 3,102,610. The metal cellular fiooring section normally comprises anupper corrugated sheet having crests and valleys and in clined sidewalls connecting adjacent ones of the crests and valleys, and a lowermetal sheet secured thereto and cooperating with the crests and theinclined side walls thereof to form a plurality of spaced, generallyparallel enclosed cells or channels.

For many years, the metal cellular flowering sections have been employedin building construction to provide versatility in electrical service.For example, a plurality of the metal cellular flooring sections aresupported by beams and girders in a building frame and are positioned inside-by-side interlocking relation and end-to-end abutting relation suchthat a plurality of the enclosed channels are provided throughout thefloor area. Concrete is applied on top of the metal cellular sections toform the floors in the resulting building. The enclosed channels,beneath the floor covering, remain available throughout the life of thebuilding as passageways for electrical wiring.

Heretofore, access to the electrical wiring beneath the concrete hasbeen accomplished by penetrating the concrete and the sheet metal crestof a cell to introduce or withdraw electrical cables. Many electricalcodes have required that the power conductors be maintained in aseparate cell apart from the low voltage signal, communications,telephone wiring. Hence, it has been necessary to provide an individualfloor outlet for power utilization and a separate floor outlet fortelephone installations. Signal equipment has demanded a third flooroutlet.

In my earlier filed copending application Ser. No. 535,282, filed Feb.14, 1966 which is assigned to the assignee of the present invention, Ihave described a novel electrical distribution system wherein a singleaccess opening is provided between a pair of underfloor cells to allow asingle lloor outlet to accommodate two types of service which arerequired by electrical codes to be delivered separately to the point ofaccess.

3,426,492 Patented Feb. 11, 1969 Objects The principal object of thepresent invention is to provide a metal cellular flooring section havingfactory installed openings in the side walls of the electrical cells toaccommodate availability of two types of electrical service at a singleaccess location.

Another object of this invention is to provide readily removable closuremeans for the openings provided with the present flooring section.

A further object of this invention is to provide a method for making thepresent metal cellular flooring sections.

Summary of the invention The present invention provides improvements ina metal cellular flooring section of the type described and wherein eachpair of adjacent cells presents spaced crests, confronting generallyvertical side walls and an intermeldiate valley disposed between theconfronting side wa s.

In accordance with the present invention, pairs of opposed openings areprovided in the corrugated metal sheet at a plurality of locationsthereon. Specifically, one of the opposed openings is formed in each ofthe confronting side walls such that each of the openings has an upperperipheral edge portion residing substantially at the level of the crestand a lower peripheral edge portion residing substantially at the levelof the intermediate valley. The opposed openings provide communicationbetween the interiors of the adjacent cells and the space above theintermediate valley.

In accordance with the present method of making the metal cellularflooring sections, the opposed openings may be formed by piercing asingle opening in the upper metal sheet before it is corrugated. Theopposed openings are placed in those regions of the upper metal sheetwhich will subsequently comprise the confronting generally vertical sidewalls and the intermediate valley. Alternatively, the opposed openingsmay be formed by piercing two separate and spaced-apart openings in theupper metal sheet prior to its being corrugated in those regions of theupper metal sheet which will subsequently comprise the confrontinggenerally vertical side walls.

Further in accordance with the present invention, readily removableclosure elements are provided for temporarily closing the opposedopenings, whereby concrete may be poured over the flooring sectionwithout entering the cells thereof. The closure elements permit easyentry into the adjacent cells after the concrete has hardened.

The above and other objects and advantages of the present invention willbecome apparent from the following detailed description by reference tothe accompanying drawings, in which:

FIGURE 1 is an isometric view of a metal cellular flooring sectionformed in accordance with the present invention;

FIG. 2 is a fragmentary plan view of a portion of the flooring sectionof FIG. 1, illustrating opposed openings provided in adjacent cellsthereof;

FIG. 3 is a cross-sectional view taken along the line III-III of FIG. 2;

FIG. 4 is a fragmentary plan view of a metal sheet having a singleopening pierced therein and which will subseqently be corrugated to formthe upper sheet of the present metal cellular flooring section;

FIG. 5 is a fragmentary plan view similar to FIG. 2, illustrating analternative embodiment of the present flooring section;

FIG.6 is a cross-sectional view taken along the line VI-VI of FIG. 5;

FIG. 7 is a fragmentary plan view of a metal sheet having a pair ofspaced-apart openings pierced therein and which will subsequently becorrugated to form the upper sheet of the present flooring section;

FIG. 8 is a fragmentary cross-sectional view, similar to FIG. 3,illustrating readily removable means for closing the opposed openings ofthe present flooring section;

FIGS. 9 and 10 are cross-sectional views similar to FIG. 8 andillustrating successive steps employed in gaining access through theopposed openings into the adjacent cells; and

FIG. 11 is a fragmentary isometric view illustrating alternative readilyremovable means for closing the opposed openings.

Flooring section-General description Referring now to FIG. 1, there isillustrated a metal cellular flooring section including an upper metalsheet 22 and a lower metal sheet 24.

The upper metal sheet 22 is corrugated and includes crests 26, valleys28 and generally vertical side walls 30 which connect adjacent ones ofthe crests 26 and the valleys 28. The upper metal sheet 22 also includesside valleys 28a and 28b. The lower metal sheet 24 is provided with afemale lip 32 and a male lip 34 adjacent the side valleys 28a and 28b,respectively. The female and male lips 32, 34 permit adjacent ones ofthe metal cellular flooring sections 20 to be interlocked.

The lower metal sheet 24 has a fiat rectangular con figuration :and issecured to the valleys 28 of the upper metal sheet 22 preferably bymeans of a plurality of spot welds 36. The lower metal sheet 24cooperates with the crests 26 and the generally vertical side walls 30to form a plurality of spaced, generally parallel enclosed cells 38.

It will be noted that each pair of adjacent cells 38 presents spacedcrests 26, confronting side walls 30 and an intermediate valley 28; andthat the confronting side walls 30 and the intermediate valley 28 definea troughlike space 39.

. Present improvement Reference is now directed to FIGS. 1-3, inclusive.In accordance with the present invention, the metal cellular flooringsection is provided with .a pair of opposed openings 40 at a pluralityof locations along the length of the flooring section 20. The opposedopenings 40 are formed in the side walls 30 of adjacent ones of thecells 38. The overall arrangement is such that the opposed openings 40provide communication between two adjacent cells 38 and the interveningspace 39 above the intermediate valley 28, as best shown in FIG. 3. Eachof the openings 40 has an upper peripheral edge portion 42 residingsubstantially at the level of one of the crests 26 and a lowerperipheral edge portion 44 residing substantially at the level of theintermediate valley 28. In this instance, the lower peripheral edgeportion 44 is defined by the lower metal sheet 24.

In FIG. 4, a portion of the upper metal sheet 22 is illustrated prior tocorrugation. Bend lines 46 and 48 are illustrated and define regions ofthe upper metal sheet 22 which will subsequently comprise theintermediate valley 28, the confronting generally vertical side walls30, and the crests 26. The opposed openings 40 are preferably formed bypiercing a single opening 50 in the sheet 22 prior to its beingcorrugated. The single opening 50 has a continuous edge extendingthrough the crests 26, the side walls 30 and the intermediate valley 28.The configuration of the single opening 50 is such that when the uppersheet 22 is corrugated, the continuous edge resides substantially in thesurface of a cylinder as shown in FIG. 2. This cylindrical configurationis preferred since the opposed openings 40 are now adapted to receive acylindrical base cup such as that base cup disclosed in my copendingapplication Ser. No. 535,282, filed Feb. 14, 1966, which is assigned tothe assignee of the present invention.

An alternative embodiment of the present metal flooring section 20 isillustrated inFIGS. 5, 6 and 7. Corresponding numerals will be employedto identify corresponding parts heretofore described.

Referring now to FIGS. 5 and 6, the metal cellular flooring section 20is provided with the opposed openings 40 each of which includes theupper edge portion 42 residing substantially at the level of the crests26 and a lower edge portion 52 which, in this instance, comprises anedge of the intermediate valley 28.

In FIG. 7, there is illustrated a portion of the upper metal sheet 22prior to corrugation. The bend lines 6 and 48 are illustrated and definethose regions of the upper metal sheet 22 which will subsequentlycomprise the crests 26, the intermediate valley 28 and the confrontingside walls 30. In this embodiment, the opposed openings 40 are formed bypiercing two separate and spaced-apart openings in those regions of theupper metal sheet 22 which will subsequently comprise the confrontingside walls 30. The configuration of the edge of the openings 40 is suchthat when the upper metal sheet 22 is corrugated, the opening edges willreside substantially in the surface of a cylinder as shown in FIG. 5.

In this embodiment, the valleys 28 remain intact throughout theirlength. Consequently, the upper metal sheet 22 may be secured to thelower metal sheet 24 by means of a spot weld 36 placed on the valley 28anywhere along its length. The spot weld 36 may be placed between theopposed openings 40.

The opposed openings 40 have been described and illustrated as having acircular presentation when viewed in plan as in FIG. 2. It is to beunderstood, however, that the opposed openings 40 could, instead, haveany other desired presentation, such as, a square, and a diamond.

Readily removable closure elements Referring now to FIG. 8, a portion ofthe metal flooring section 20 is shown supported horizontally on a beam54 preparatory to receive a layer of concrete. Prior to pouring theconcrete, it is necessay to close the opposed openings 40 so as toprevent ingress of the concrete into the interior of the cells 38.

In accordance with the present invention, the means for closing theopposed openings 40 preferably comprises a plug 56 which, in thisinstance, has a cylindrical configuration. A magnetically susceptibleelement 57, such as a nail, may be positioned at the center of the plug56 to assist in locating the plug 56. Alternatively, the element 57 maycomprise a magnet.

The plug 56 is inserted into the opposed openings 40 and, as shown inFIG. 9, has an upper surface 58 disposed at or above the level of thecrests 26. The plug 56 completely closes the opposed openings 40 andprevents ingress of concrete into the cells 38. The plug 56 may beformed from any suitable material which will resist being crushed by theconcrete poured thereover. Examples of suitable materials include foamedplastics, such as foamed polystyrene, foamed polyurethane, foamedpolyethylene; thin gauge metals, cardboard, lightweight concrete, foamedglass and the like.

In FIG. 9, a layer of concrete 60 has been poured over the metalcellular flooring section 20. In order to gain access to the adjacentcells 38, a hole is drilled through the concrete 60, for example, bymeans of a suitable hole saw 62 in a manner well known in the art.Positioning of the hole saw 62 directly over the plug 56 is facilitatedby the element 57 in a manner also well known in the art. The plug 56 isthen removed as shown in FIG. 10 and an opening 64 remains which permitsaccess to the interiors of the adjacent cells 38.

Referring now to FIG. 11, the opposed openings 40 could, instead, beclosed by securing a sheet material 66 across the opposed openings 40and to the crests 26, the side walls 30 and the valley 28. Suitablematerials to be used include various cloths, stiff papers, thin gaugemetal, tapes, films and the like.

Summary From the foregoing detailed description, it should be readilyapparent that the present invention provides an improved metal cellularflooring section wherein access to the interiors of the several cellsmay be readily achieved. Furthermore, the present metal cellularflooring section is provided with prepunched openings arranged toprovide communication between the interiors of adjacent cells and thespace between the adjacent cells at one location in the flooringsection. Access to the adjacent cells is easily attainable after a layerof concrete has been poured over the flooring section and has hardened.This arrangement is exceedingly advantageous in that two adjacent cellsmay be activated simultaneously by drilling one hole in the concreterather than by drilling two holes as heretofore required.

The present invention further provides readily removable closureelements which can be installed in the factor-y or in the field, asdesired, to close the opposed openings. The closure elements preventingress of concrete into the cells and are readily removable when thecells of the flooring section are activated.

I claim as my invention:

1. In a metal cellular flooring section adapted to be supportedhorizontally and receive and support a layer of concrete, said flooringsection comprising a corrugated upper metal sheet having crests andvalleys and generally vertical side walls connecting adjacent ones ofsaid crests and said valleys, and a lower metal sheet secured to saidcorrugated sheet and cooperating with said crests and said side walls toform a plurality of spaced, generally parallel cells, each pair ofadjacent cells presenting spaced crests, confronting side walls and anintermediate valley disposed between said confronting side walls, theimprovement comprising:

at least two opposed unobstructed openings, one formed in each of saidconfronting side walls, said opposed openings providing communication atone location in said fioornig section, between the interiors of saidadjacet cells and the space above said intermediate valley.

2. The improvement as defined in claim 1 wherein each of said opposedopenings has an upper edge portion residing substantially at the levelof a said crest and a lower edge portion residing substantially at thelevel of said intermediate valley.

3. The improvement as defined in claim 1 including readily removableclosure means for closing each of said openings.

4. The improvement as defined in claim 3 wherein said readily removableclosure means comprises a plug inserted between said adjacent cells intosaid openings and having an upper surface disposed at or above the levelof said spaced crests.

5. The improvement as defined in claim 3 wherein said readily removableclosure means comprises a sheet material applied over said openings andsecured to the corrugated metal sheet.

6. The improvement as defined in claim 1 wherein said upper edge portionof each of said openings has an arcuate configuration and extends intoone of said spaced crests.

7. The improvement as defined in claim 1 wherein said opposed openingsare formed in said corrugated sheet by a single piercing operation suchthat a continuous edge is provided extending through the said spacedcrests and the said confronting side walls of said adjacent cells andthe said intermediate valley, said continuous edge residingsubstantially in the surface of a cylinder.

8. The improvement as defined in claim 1 wherein the generally verticalside wall at each of the opposite longitudinal sides of said flooringsection, is imperforate.

References Cited UNITED STATES PATENTS 538,256 4/1895 Hayes 526741,281,453 10/1918 White 52-451 1,995,496 3/1935 Burgess 52-588 X2,694,475 11/1954 Crafton 52-22O X 3,166,631 1/1965 Reiland 52-221 XFOREIGN PATENTS 617,727 2/ 1949 Great Britain. 389,864 7/1965Switzerland.

DAVID J. WILLIAMOWSKY, Primary Examiner.

D. L. TAYLOR, Assistant Examiner.

U.S. Cl. X.R., 526l3

